Closing a chamber of a container for a pharmaceutical product

ABSTRACT

A device for closing a chamber of a container having an opening for accessing the chamber comprises a plunger, a plunger seat, a container carrier and a spacer. The plunger seat releasably holds the plunger in a predefined alignment. The container carrier is arranged to be connected to the container in a predefined position and alignment in relation to the opening of the container. The spacer is arranged to position and align the plunger seat adjacent to and distant from the container carrier such that the opening of the container is open when the container is connected to the container carrier.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of prior application U.S.application. Ser. No. 15/531,884, having a 371(c) date of May 31, 2017,now U.S. Pat. No. [tbd], which is a national phase application ofPCT/EP2015/078607, filed Dec. 4, 2015, which claims priority to EP 14196 514.5, filed Dec. 5, 2014, each of which is incorporated byreference herein in its entirety.

TECHNICAL FIELD

The present invention relates to a device for closing a chamber of acontainer having an opening for accessing the chamber. Such devices canbe used in processes of preparing pharmaceutical products and containersfilled with pharmaceutical products.

BACKGROUND

Many pharmaceutical products, pharmaceutical substances or simplypharmaceuticals are processed and/or applied in liquid form. For this,the liquid pharmaceuticals are filled into containers such as in vials,syringes or the like. Also, many pharmaceuticals and particularlybiopharmaceuticals which frequently are highly unstable in liquid formare often provided in a lyophilized form in which they are essentiallymore stable and robust compared to their liquid forms. The lyophilizedpharmaceuticals can also be filled and provided in containers. Beforebeing applied to patients, they are reconstituted or solved in a diluentor similar liquid.

For allowing injection such as subcutaneous, intramuscular, intradermalor intravitreal injection of a pharmaceutical product, which often ismost efficient and preferred, pharmaceuticals can be provided directlyin syringes such as in staked-in needle pre-filled syringes ready forbeing applied. In cases where lyophilised pharmaceuticals are involveddual chamber syringes are commonly used in which one chamber houses thelyophilised pharmaceutical and the other chamber the diluent. When beingapplied, an activation rod is pushed into the double chamber syringe intwo steps. In a first step, it is pushed far enough for bringing thediluent and pharmaceutical together and in a second step it iscompletely pushed in order to provide the liquidized or solvedpharmaceutical out of the needle.

For closing containers filled with pharmaceuticals, it is known to userubber plungers. Thereby, a plunger is usually arranged into an openingof a container for sealing it. On an industrial level such plungersusually are automatically pushed or sucked into the openings of thecontainers after the pharmaceutical is arranged inside the chambers ofthe containers. Particularly since the containers and the plungers haveto be kept uncontaminated, closing the containers is often performed ina sterile environment. However, namely on an industrial level theclosing of containers in a sterile manner when preparing the containerscomprising the pharmaceutical can be cumbersome and cause an undesirableeffort.

In particular, closing containers in the process of preparinglyophilized pharmaceuticals inside the containers can be comparablycomplicated. Notably, when lyophilized pharmaceuticals are prepared andpackaged in dual chamber syringes closing the syringes by providingplungers into their openings within the process of preparing thesyringes and the pharmaceuticals can be comparably difficult and causingcomparably high costs. However, since the lyophilized pharmaceuticals indouble chamber syringes can be comparably simply processed such astransported, stocked, sold, applied and the like, efficient preparationof double chamber syringes is desired.

Therefore, there is a need for a device or system allowing forefficiently closing containers such as double chamber or other syringeswithin a process of preparing the containers wherein, for example, suchprocess can comprise lyophilisation of a product inside the container.

SUMMARY OF THE INVENTION

According to the invention this need is settled by a device for closinga chamber of a container having an opening for accessing the chamber.The device comprises a plunger, a plunger seat, a container carrier anda spacer. The plunger seat releasably holds the plunger in a predefinedalignment. The container carrier is arranged to be connected to thecontainer in a predefined position and alignment in relation to theopening of the container. The spacer is arranged to predefine a positionand alignment of the plunger seat in relation to the container carrier.In a predefined distant position of the device, the plunger seat islocated distant from the opening of the container when the container isconnected to the container carrier such that the opening of thecontainer is open. In a predefined near position of the device, theplunger seat is arranged adjacent to the opening of the container whenthe container is connected to the container carrier such that theplunger is providable into the opening of the container for closing thecontainer.

In connection with the plunger seat the term “releasably” can relate toa connection between the plunger seat and the plunger which is strongenough in order that the plunger seat carries the plunger and is slightenough such that the plunger can easily be separated from the support.In particular, in accordance with the invention the plunger seat canhold the plunger such that it carries the plunger and at the same timethe plunger can conveniently be released from the plunger seat for beingprovided to the container without being impaired or damaged or the like.For example, such connection can be embodied by holding the plunger byfriction in the plunger seat.

The term “predefined” as used herein, generally, relates toarrangements, positions or situations for which the device or particularfeatures thereof are embodied. For example, the device can haveparticular means or measures for clearly target a particular position orsituation. By such means the device can predefined such particularposition or situation. The term is to distinguish from not being clearlydefined such as a position which might by accident or within a unclearmovement be achieved. For example, if a plunger is manually providedinto a container and thereby being transferred through the distantposition defined herein such positioning is not predefined.

More particular, the term “predefined” in connection with the distantand near positions of the device can relate to an arrangement of thedevice allowing to ensure that the distant and near positions are wellachieved. In particular, the device can be embodied with particularmeans as described in more detail below by way of exemplary embodimentsfor exactly providing the near and distant positions such that thesepositions are well defined. Thereby, such means can allow either aconnection of the plunger seat and the container carrier which isadjustable between the distant and near positions. Or, such means canallow a corresponding connection of the device and the container itself.

The term “predefined alignment” with respect to the plunger held by theplunger seat of the support can relate to a rotational and directionalarrangement of the plunger. In particular, the rotational anddirectional arrangement can be predefined or adjusted for being furtherprocessed or to a specific aim. This can allow the plunger to be easilyprovided into the opening of the container for closing it. Inparticular, the term can relate to an alignment of the plunger allowingfor straightly pushing or sucking it into the opening of the containerwhen the container is connected to the container carrier.

The term “predefined position and alignment” with respect to thecontainer carrier can particularly relate to an arrangement ensuringthat the opening of the container is suitably located and suitablyadjusted or rotated and directed. Together with the arrangement of theplunger seat and the spacer, this allows for well defining the positionof the plunger in relation to the opening of the container such that theplunger can be easily provided into the opening of the container forclosing it. Particularly, the location and adjustment of the plungerseat can allow for straightly pushing or sucking the plunger into theopening of the container.

The term “distant” in connection with the plunger seat in relation tothe opening of the container connected to the container carrier canrelate to an arrangement of the plunger in which on one hand it does notcontact the opening of the container or an edge of it and on the otherhand there is a free space in between the plunger and the opening. Likethis, it can be assured that the opening is kept open and accessible.

The term “adjacent” in connection with plunger seat in relation to theopening of the container connected to the container carrier can relateto an arrangement in which the plunger seat contacts or nearly contactsthe container at its opening. It can relate to an arrangement in whichthe plunger held in the plunger seat is close enough to the opening forbeing efficiently provided into the container. In such arrangement theopening of the container may not or not fully be open.

The term “open” in connection with the container being connected to thecontainer connection and the plunger being held by the plunger seat canrelate to an accessibility of the chamber of the container from itsoutside. For example, when the container is open substances can befilled into the chamber of the container through its opening or gasessuch as steam can escape the chamber, e.g. during lyophilisation.

The container can be suitable for providing a substance intended forlyophilisation. For example, it can be a vial or a syringe. Inparticular, it can be a double chamber syringe which, in a finallyprepared status, has one chamber containing a loyphilisate orfreeze-dried substance or product and another chamber containing areconstitution medium such as a liquid diluent.

The device according to the invention can particularly be beneficial inprocesses of preparing chemical or biological pharmaceutical substancesin a ready-to-use form. In particular, it can increase efficiency ofpackaging the substances in containers, e.g. in a preparation processincluding drying such as freeze-drying. The terms “pharmaceuticalsubstance”, “pharmaceutical product”, “pharmaceutical” are synonymouslyused herein. Also, the terms “freeze-drying” and “lyophilizing” are usedsynonymously herein.

As explained in more detail below with respect to preferred embodiments,the plunger seat, the container carrier and the spacer can be embodiedin one single piece for example made of a plastic material. Thereby, itscontainer carrier, plunger seat and spacer can be fixedly arranged inrelation to each other. Alternatively, the plunger seat together with afirst portion of the spacer can form a first single piece of the deviceand the container carrier together with a second portion of the space asecond single piece of the device.

The device, can be made of any suitable material wherein forpharmaceutical application it can particularly be made of a sterilisablematerial. Such sterilisable material can for example be a plasticmaterial which can be additionally beneficial with respect tomanufacturing costs and flexibility.

The device according to the invention allows for efficiently closingcontainers filled with pharmaceuticals. It can be obtained in apre-sterilized form which allows for easily integrating it in a processof preparing pharmaceuticals including packaging. Since the plunger seataligns the plunger and the container carrier aligns and positions theopening of the container in relation to the plunger seat the plunger canefficiently be provided into the opening for closing it. Further, sincethe spacer between the container carrier and the plunger seat positionsand aligns the plunger seat adjacent to or distant from the containercarrier the opening of the container is open when the device is in thedistant position, e.g. when the container is connected to the containercarrier. Thereby, the pharmaceutical inside the container can beprocessed in a comparably unimpaired manner wherein the device and thecontainer form a unit during plural steps of the preparation process. Inparticular, such arrangement allows for efficiently lyophilising thepharmaceutical inside the container wherein the device is connected tothe container such that it is not necessary to change the assembly afterlyophilisation for closing the container. This allows for providing anefficient process of preparing containers comprising pharmaceuticals,particularly, when such process includes lyophilisation of thepharmaceutical.

Preferably, the plunger is made of an elastically deformable material,e.g., an elastic plastic material such as butyl or a rubber material.Such an elastically deformable material allows for the plunger totightly close the container. In particular, when being pushed or suckedinto the opening of the container the plunger can be compressed suchthat due to its elasticity it presses itself against and tightlyconnects to the side wall of the container or a neck thereof.

Preferably, the plunger seat comprises a through-hole dimensioned toreleasably hold the plunger when being arranged in the though-hole.Thereby, the through hole can be sized to hold the plunger by friction.Alternatively or additionally, the interior of the through-hole can beequipped with a bulge which corresponds to ribs of the plunger. Inparticular, one plunger rib resides on the bulge and, as the plunger iselastic, the device is releasable holding the plunger. Such anarrangement of the plunger seat is particularly suitable for plungersbeing made of an elastically deformable material as mentionedhereinbefore. It allows for a comparably easy construction of theplunger seat. In particular no clamping means, other holding means orthe like are necessary.

In a first preferred embodiment, the device comprises a support havingthe plunger seat, the container carrier and the spacer between theplunger seat and the container carrier, wherein the container carriercomprises a clamping portion for clamping a section of the containeradjacent to its opening and the container carrier passes over into thespacer via a step arranged for contacting an edge of the opening of thecontainer. In particular, in the first embodiment the support can be aone-piece construction whereas the plunger forms another separate piece.The step can form a right angle with the at least one cylinder segmentof the clamping portion and the spacer. It can also form any other angleor a curve without a particular angle.

Thereby, the clamping portion of the container carrier preferablycomprises at least one cylinder segment between which the section of thecontainer adjacent to its opening is clampable. Such a clampingmechanism allows for precisely and safely connect the container. Also,it allows for an efficient manufacture of the device and particularlyits container carrier.

The spacer of the support preferably comprises at least one cylindersegment connecting the clamping portion of the container carrier via thestep and the plunger seat. The at least one cylinder segment of thespacer can also be a full cylinder. Such a spacer with at least onecylinder segment can be efficiently embodied particularly when thecontainer carrier comprises the at least one cylinder segment. In suchan embodiment, the number of the cylinder segments of the spaceradvantageously corresponds to the number of the cylinder segments of theclamping portion of the container carrier. In particular, each cylindersegment of the spacer can pass over to one of the cylinder segments ofthe clamping portion of the container carrier via a section of the step.

In a variant of the first preferred embodiment, each of the at least onecylinder segment of the clamping portion of the container carrier isconnected to one of the at least one cylinder segments of the spacer viathe step and the at least one cylinder segment of the clamping portionhas an inner diameter which is smaller than an inner diameter of the atleast one cylinder segment of the spacer.

The inner diameter of the at least one cylinder segment of the clampingportion can particularly be slightly smaller than the outer diameter ofthe section of the container adjacent to its flange portion. Since theinner diameter of the at least one cylinder segment of the clampingportion is smaller, the step extends outwardly from the clampingportion. Like this the container carrier and particularly its clampingportion can be clamped on the container by elastically deforming its atleast one cylinder segment in an outward direction. The inner diameterof the at least one cylinder segment of the spacer can be dimensionedsuch that the flange portion of the container fits inside. I.e. theinner diameter of the at least one cylinder segment is identical orbigger than the outer diameter of the flange portion of the container.

Thereby, the step of the device preferably is arranged for contactingthe edge which has a finger flange portion formed around the opening ofthe container. Such an arrangement of the step allows the device beingapplied with containers having a finger flange such as syringes having afinger flange near its opening for arranging the fingers while pushingthe activation rod.

In another variant of the first preferred embodiment, each of the atleast one cylinder segment of the clamping portion of the containercarrier is connected to one of the at least one cylinder segment of thespacer via the step and the at least one cylinder segment of the spacerhas an inner diameter which is smaller than an inner diameter of the atleast one cylinder segment of the clamping portion.

The inner diameter of the at least one cylinder segment of the clampingportion can particularly be slightly smaller than the outer diameter ofthe section of the container adjacent to the opening. Like this, thecontainer carrier and particularly its clamping portion can be clampedon the container by elastically outwardly deforming its at least onecylinder segment. Since the inner diameter of the at least one cylindersegment of the spacer is smaller the step extends inwardly from theclamping portion. The container can be pushed into the at least onecylinder segment of the clamping portion of the container carrier untilthe edge of the opening of the container abuts the edge of the support.Like this, the support can be precisely connected to the container.

Within the first preferred embodiment, the plunger seat preferablycomprises at least one protrusion laterally projecting over the spacer.Such a protrusion can be used as a finger flange being embodied in thesupport. For example, such an embodiment can be used with a syringe nothaving an own finger flange. It allows for providing the container suchas a syringe with a finger flange which, e.g., can be necessary forapplying an activation rod into the syringe for providing the substanceor product out of the syringe. The protrusion can also be used in anauto-injector. Also, it allows for efficiently handling the device suchas, e.g., for removing the device at the end of processing.

In a second preferred embodiment, the device has a support and a holderwherein the support comprises the plunger seat and a support part of thespacer, the holder comprises the container carrier and a holder part ofthe spacer, and the support part of the spacer and the holder part ofthe spacer are arranged to interengage to be connected in the distantposition and to be connected in the near position. In this context theholder and support parts are formed to be capable of being connected inthe distant position as well as in the near position whereas they areonly connected in one of the positions at a time.

The term “interengage” in this context relates to the support and holderparts of the spacer interacting in a predefined manner. Particularly,the support and holder parts can be fixedly or releasably connected toeach other. Thereby, the arrangement of the support and holder parts ofthe support allows to position and align the plunger seat and thecontainer carrier in a predefined manner. The spacer can be arrangedsuch that the support part and the holder part are guided from thedistant position to the near position.

In a variant of the second preferred embodiment, the holder part of thespacer and the support part of the spacer interengage by forming asnap-in connection. For example, the support part of the spacer can haveat least one elastically movable cylinder segment with a bulge on itsouter surface and the holder part of the spacer can be embodied as ahollow cylinder having a sidewall with a thicker section and a thinnersection. In such an embodiment of the spacer, the support part cansnap-in the holder part by pressing the at least one cylinder segmentinto the hollow cylinder until the bulge engages behind the thickersection of the hollow cylinder. In this position the support part isconnected to the holder part, e.g. in the near position. As othersimilar embodiments, the support and holder parts can also oppositely beformed, i.e. the holder part has the at least one cylinder segment andthe support part has the hollow cylinder. Or, one of the support andholder parts can be embodied as rod with a bulge on its circumferenceand the other one of the support and holder parts is correspondinglyembodied as flexible hollow cylinder having a sidewall or sidewallsegments of varying thicknesses.

The snap-in connection formed by the holder part of the spacer and thesupport part of the spacer preferably is arranged to connect the holderpart of the spacer and the support part of the spacer in plural distinctpositions. Such multi-position snap-in can be achieved in a spacer asdescribed hereinbefore, i.e. comprising the support part having at leastone elastically movable cylinder segment with a bulge on its outersurface and the holder part embodied as a hollow cylinder having thesidewall with the thicker section and the thinner section, by providinga groove in the thicker section of the sidewall. In such an embodimentof the spacer, the support part can snap-in the holder part in at leasttwo positions. In one position, e.g. the distant position, the bulge ofthe support section is arranged in the groove of the thicker section ofthe hollow cylinder of the holder section and in another position, e.g.,the near position, the bulge engages behind the thicker section of thehollow cylinder. Again, other similar embodiments are possible asdescribed above. Such a multi-position snap-in spacer allows forconnecting the support with the holder in the distant position where thecontainer is open and in the near position where the container is closedor nearly closed.

In another variant of the second preferred embodiment, the holder partof the spacer comprises an inclined ramp and the support part of thespacer comprises a slider, wherein the slider is movable along the rampfrom the distant position in which the plunger seat of the support isdistant and laterally displaced from the container carrier of the holderto the near position in which the plunger seat of the support isadjacent and straightly directed to the container carrier of the holder.The ramp can have a straight or bent surface along which the slider canmove while being in contact. The term “inclined” can relate to a slantinclination of the ramp with respect to a direction the support and theholder have to be moved to each other in order in order to bring theplunger and the opening of the container together. The slider cancomprise or be shaped as a post or a similar structure suitable formoving in contact with and along the ramp. The ramp and the slider allowfor precisely moving the support and the holder towards each otherwherein this movement is not in a straight direction but in a indirection sideways or laterally to each other. Thus, the ramp allows formoving the support and the holder towards each other and at the sametime laterally offsetting the support and the holder to each other.

Thereby, the holder part of the spacer comprises a distant fastener atone end of the ramp for fastening the slider of the support part of thespacer in the distant position and a near fastener at the other end ofthe ramp for fastening the slider of the support part of the spacer inthe near position. The distant fastener can, e.g., be embodied as a hookclamping the slider when the holder is in the distant position. The nearfastener can, e.g., be formed as a recess in which the slider droppedwhen the holder is in the near position. The two fasteners allow forsecuring the holder and the support in the distant and near positions toeach other. An unintentional movement can thereby be prevented.

The support preferably comprises an access through-hole which isstraightly directed to the container carrier of the holder when thedevice is in the distant position. Such an access through-hole allowsfor accessing the interior of the container through the device which canincrease efficiency when processing the container. In particular, aliquid or other substance can be filled into the container via theaccess through-hole and the proximal opening of the container wherein itis not required to remove the support.

Preferably, the support of the device has a support base plate on whichthe plunger seat and the support part of the spacer are arranged.Similarly, the holder preferably has a holder base plate on which thecontainer carrier and the holder part of the spacer are arranged. Such asupport base plate and/or holder base plate allows for efficientlymanufacturing and handling the support within a process of preparing thecontainer and the pharmaceutical.

Preferably, the support comprises at least one further plunger seat andthe holder comprises at least one further container carrier, wherein theplunger seat and the at least one further plunger seat are located onthe support in correspondence with the container carrier and the atleast one further container carrier of the holder. With such anarrangement, plural nested plungers can be obtained in the support andprovided to respective plural nested containers arranged in the holder.This allows for efficiently processing and preparing a plurality ofcontainer which can be desired in industrial processes.

These and other aspects of the invention will be apparent from andelucidated with reference to the embodiments described hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The device according to the invention is described in more detailhereinbelow by way of exemplary embodiments and with reference to theattached drawings, in which:

FIG. 1 shows a perspective view of a first embodiment of a deviceaccording to the invention;

FIGS. 2A-2J show perspective partial views of a first embodiment of afacility for preparing a syringe using the device of FIG. 1 ;

FIG. 3 shows a perspective view of a second embodiment of a deviceaccording to the invention;

FIGS. 4AA′-4AE′ show perspective partial views of a second embodiment ofa facility for preparing a syringe using the device of FIG. 3 ;

FIGS. 4BF′-4BK′ show further perspective partial views of the facilityof FIGS. 4AA′-4AE′;

FIG. 5 shows a perspective view of a third embodiment of a deviceaccording to the invention;

FIGS. 6A″-6J″ show perspective partial views of a third embodiment of afacility for preparing a syringe using the device of FIG. 5 ;

FIG. 7 shows a side view of a spacer of the device of FIG. 5 in apreliminary position;

FIG. 8 shows a side view of the spacer of FIG. 7 in a distant position;

FIG. 9 shows a side view of the spacer of FIG. 7 in a near position;

FIGS. 10A″′-10J″′ show perspective partial views of a fourth embodimentof a facility for preparing a syringe using a fourth embodiment of adevice according to the invention;

FIG. 11 shows a side view of a spacer of the device of FIGS. 10A″′-10J″′in a preliminary position;

FIG. 12 shows a side view of the spacer of FIGS. 10A″′-10J″′ in adistant position;

FIG. 13 shows a side view of the spacer of FIGS. 10A″′-10J″′ in anintermediate position; and

FIG. 14 shows a side view of the spacer of FIGS. 10A″′-10J″′ in a nearposition.

DETAILED DESCRIPTION

In the following description certain terms are used for reasons ofconvenience and are not intended to limit the invention. The terms“right”, “left”, “up”, “down”, “under” and “above” refer to directionsin the figures. The terminology comprises the explicitly mentioned termsas well as their derivations and terms with a similar meaning. Also,spatially relative terms, such as “beneath”, “below”, “lower”, “above”,“upper”, “proximal”, “distal”, and the like, may be used to describe oneelement's or feature's relationship to another element or feature asillustrated in the figures. These spatially relative terms are intendedto encompass different positions and orientations of the devices in useor operation in addition to the position and orientation shown in thefigures. For example, if a device in the figures is turned over,elements described as “below” or “beneath” other elements or featureswould then be “above” or “over” the other elements or features. Thus,the exemplary term “below” can encompass both positions and orientationsof above and below. The devices may be otherwise oriented (rotated 90degrees or at other orientations), and the spatially relativedescriptors used herein interpreted accordingly. Likewise, descriptionsof movement along and around various axes includes various specialdevice positions and orientations.

To avoid repetition in the figures and the descriptions of the variousaspects and illustrative embodiments, it should be understood that manyfeatures are common to many aspects and embodiments. Omission of anaspect from a description or figure does not imply that the aspect ismissing from embodiments that incorporate that aspect. Instead, theaspect may have been omitted for clarity and to avoid prolixdescription. In this context, the following applies to the rest of thisdescription: If, in order to clarify the drawings, a figure containsreference signs which are not explained in the directly associated partof the description, then it is referred to previous or followingdescription sections. Further, for the reason of lucidity, if in asection of a drawing nor all features of a part are provided withreference signs it is referred to other sections of the same drawing.Like numbers in two or more figures represent the same or similarelements.

In FIG. 1 a first embodiment of a device 1 according to the invention isshown. The device 1 comprises a support with a plunger seat 11, acontainer connector 13 as container carrier and a spacer 12 between theplunger seat 11 and the container connector 13. The support is embodiedas one piece made from a plastic material. The plunger seat 11 is formedas a longitudinal plate 112 of a constant thickness having plane top andbottom surfaces. In a top view the longitudinal plate 112 widens towardsits middle such that a central section of the plate 112 has the largestwidth. In this central section of the longitudinal plate 112 a centralthrough-hole 111 is arranged.

On its bottom surface the longitudinal plate 112 passes over into thespacer 12. The spacer 12 comprises two opposing cylinder segments 121.The cylinder segments 121 surround a circular cylindrical interior. Eachof the two lateral sections of the longitudinal plate 112 form aprotrusion 113 laterally projecting over the spacer 12.

On their bottom ends each of the cylinder segments 121 of the spacer 12pass over into a cylinder segment 131 of a clamping portion of thecontainer connector 13 via step 14. The cylinder segments 131 of theclamping portion of the container connector 13 also surround a circularcylindrical interior. The two cylinder segments 131 of the clampingportion of the container connector 13 have an inner diameter which issmaller than an inner diameter of cylinder segments 121 of the spacer12. Thus, the step 14 inwardly extends from the cylinder segments 121 ofthe spacer 12 to the cylinder segments 131 of the clamping portion ofthe container connector 13.

FIGS. 2A-2J shows steps of a first embodiment of a method for preparinga first embodiment of a double chamber staked-in needle syringe 6 ascontainer. The first method is implemented in a first embodiment of afacility for preparing the syringe 6.

The syringe 6 has a distal end side, a proximal end side opposite to thedistal end side and a cylindrical body portion 63 with an interiorbetween the distal end side and the proximal end side. A distal openingprovided with a needle is arranged at the distal end side of the syringe6. The needle is covered and protected by a rigid needle shield 64.

The proximal end side of the syringe 6 has a proximal opening 61 foraccessing the interior of the body portion 63 surrounded by a fingerflange 62. The distal end side, the body portion 63 and the proximal endside with its finger flange 62 are integrally made of glass, i.e. areone piece.

In the step of FIG. 2A of the first method the syringe 1 is arranged ina respective seat of a holder 4 of the first facility. The seat of theholder 4 has two parallel supporting arms 41 which receive the bodyportion 61 of the syringe 6 in a vertical alignment in which theproximal opening 61 is at a top end of the syringe 6 and the rigidneedle shield 64 is at a bottom end of the syringe 6. The syringe 6 isabutting with its finger flange 62 onto the top end of the uppersupporting arm 41 of the holder 4. Thereby, the syringe 6 is verticallyhanging between the supporting arms 41 of the holder.

Below the distal end side of the syringe 6 two parallel guiding rails 5of the first facility are arranged. The rigid needle shield 64 of thesyringe 6 extends downwardly through the guiding rails 5. The twoguiding rails 5 have a distance from each other suitable for the rigidneedle shield 64 to fit in between or to pass through but not for thebody portion 63 of the syringe 6.

In the step of FIG. 2B of the first method the holder 4 together withthe syringe 6 is transferred along the guiding rails 5 by a transporterof the facility to a feeding station of the first facility. There asubstance such as a liquid pharmaceutical substance or particularly aliquid biopharmaceutical substance is fed into the interior of thesyringe 6. For this purpose a discharge pipe of a substance dosingfeeder 91 of the first facility is entered through the proximal opening61 into the interior of the syringe 6. Then the substance is filled intothe interior of the syringe 6 wherein the syringe 1 is aligned by theholder 4 and the guiding rails 5 in order to allow for preventingleakage and contamination. After feeding, the substance is lying on thebottom of the interior of the syringe 6, i.e. at the distal end side ofthe syringe 6.

In the step of FIG. 2C the syringe 1 and the holder 4 are furthertravelled along the guiding rails 5 by the transporter of the facility.The guiding rails 5 are raising such that the distance between theguiding rails 5 and the holder 4 decreases. Since the body portion 63 ofthe syringe 6 does not fit between the guiding rails 5 the distal endside of the body portion 63 abuts onto the guiding rails 5. Like thisthe syringe 6 is lifted such that the finger flange 62 is distant fromthe holder 4.

As shown in the step of FIG. 2D, in this lifted position the support ofthe device 1 is clipped on the syringe 6. Inside the through-hole 111 ofthe plunger seat 11 of the support a rubber plunger 15 of the device 1is arranged. The through-hole 111 is dimensioned to releasably hold theplunger 15 by friction. Thereby, the plunger 15 extends the through-hole111 downwardly to a certain extent.

The clamping portion of the container connector 13 and in particular itscylinder segments 131 clamp the body portion 63 of the syringe 6adjacent to its finger flange 62, i.e. at a section of the syringe 6adjacent to its proximal opening 61. The step 14 of the support of thedevice 1 contacts an edge of the finger flange 62 of the syringe 6. Theinner diameter of the two cylinder segments 131 of the clamping portionis slightly smaller than the outer diameter of the body portion 63 ofthe syringe 6. Thus, for the syringe 6 being arranged between the twocylinder segments 131 the clamping portion has to be elasticallyoutwardly bent such that it is tensioned. Like this the body portion 63is attached in between the cylinder segments 131 of the containerconnector 13.

The inner diameter of the cylinder segments 121 of the spacer 12 aredimensioned such that the finger flange 62 of the syringe 6 fits inbetween. I.e. the inner diameter of the cylinder segments 121 of thespacer 12 is identical or slightly bigger than the outer diameter of thefinger flange 62 of the container 6.

Due to the height of the spacer 12 of the support of the device 1 theplunger 15 is held distant from the proximal openings 61 of the syringe6 when the finger flange 62 contacts the step 14. Thus, in this positionthe proximal opening 61 and the interior of the syringe 6 are open andaccessible. The device 1 is in a distant position.

In the step of FIG. 2E the syringe 6 is transferred by the transporterof the first facility to a freeze-drying block 7 of a freeze-dryer ofthe first facility. Thereby, the device 1 still is in the distantposition. The freeze-drying block 7 is made of aluminium and has pluralreceptacles 71. Each receptacle 71 is embodied as a bore with a profileshaped to receive one syringe 6. In particular, the profiles of thereceptacles 71 have a lower needle section 711 dimensioned to receivethe needle together with the rigid needle shell 64 of the syringe 6 andan upper body section 713 dimensioned to contact the lower part of thebody portion 63 of the syringe 6. Between the needle section 711 and thebody section 713 a shoulder section 712 is formed which is dimensionedto receiving the distal end side of the syringe 6. The top side of thebody section 713 passes over into a conical entrance section 714 whichallows for conveniently entering the syringe 6 into the receptacle 71.

When the syringe 6 is arranged in one of the receptacles 71 of thefreeze-drying block 7, heat is provided via the side walls of the bodyportions 713 of the receptacles 71 and the side walls of the bodyportion 63 of the syringe 6 to the liquid substance being at the bottomof the body portions 63 of the syringe 6. Like this, the heat isconductively transferred to the substance and simultaneously the sectionof the body portion 63 of the syringe 6 where the substance is locatedis insulated with respect to heat irradiation. By conductively providingthe heat to the substance a homogeneous heat transfer and lyophilisationis achieved. Furthermore, the isolation allows for preventing thesubstance being heated by irradiation during lyophilisation but, e.g.,mainly by conductive heat transfer. Since the plunger 15 is held by thesupport of the device distant from the proximal opening 61 of thesyringe 6 gas and steam escapes the syringe 6 via the proximal opening61 during lyophilisation.

In the step of FIG. 2F, after lyophilisation of the substance, thesupport of the device 1 is lowered top down on the syringe 6 and theplunger 15 is connected to the proximal opening 61 of the syringe 6. Thedevice now is in a near position. Since resulting from lyophilisation ofthe substance an underpressure is induced in the interior of the syringe6 the plunger 15 is sucked into the syringe 6 and its interior isclosed. Thereby, the plunger 15 is moved as far into the syringe 6 suchthat two chambers are formed inside the syringe 6 wherein the plunger 15seals a distal chamber housing the lyophilised substance from a proximalchamber.

In step of FIG. 2G the syringe 6 is again positioned in the holder 4 asdescribed above wherein the rigid needle shield 64 extends through theguiding rails 5. As shown in the step of FIG. 2H, the holder 4 togetherwith the syringe 6 is then transferred along the guiding rails 5 by thetransporter of the first facility to the feeding station of the firstfacility. There, a discharging pipe of a medium dosing feeder 92 of thefirst facility is entered through the though-hole 111 of the plungerseat 11 and the proximal opening 61 into the interior of the syringe 6.The medium dosing feeder 92 feeds a reconstitution medium or diluent inthe proximal chamber of the syringe 6. After being fed, thereconstitution medium lies on the top of the plunger 15 inside thesyringe 6, i.e., in its proximal chamber.

In the step of FIG. 21 a further plunger is pressed into the proximalopening 61 of the syringe 6 by means of a tube 93 of a sealer of thefirst facility. Thereby, the proximal opening 61 of the syringe 6 issealed by the further plunger. The syringe 6 is arranged in the guidingrails 5 wherein the distal end side of the body portion 63 abuts therails 5. Like this the pushing force induced on the syringe 6 by thetube 93 of the sealer is received by the guiding rails 5.

After the proximal opening 61 of the syringe 6 being sealed, the holder4 together with the syringe 6 is transferred by the transporter to anoptical inspection station of the first facility. There, the quality ofthe lyophilised substance is verified. In the step of FIG. 2J thefinally prepared syringe 6 being ready to be delivered is shown.

As described hereinabove, the syringe 6 is arranged in an uprightposition throughout the complete preparation process. This allows for anefficient handling and processing.

In FIG. 3 a second embodiment of a device 10 according to the inventionis shown. The device 10 comprises a support with a plunger seat 110, acontainer connector 130 as container carrier and a spacer 120 betweenthe plunger seat 110 and the container connector 130. The support isembodied as one piece made from a plastic material. The plunger seat 110is formed as a longitudinal plate 1120 of a constant thickness havingplane top and bottom surfaces. In a top view the longitudinal plate 1120widens towards its middle such that a central section of the plate 1120has the largest width. In this central section of the longitudinal plate1120 a central through-hole 1110 is arranged.

On its bottom surface the longitudinal plate 1120 passes over into thespacer 120. The spacer 120 comprises a hollow cylinder segment 1210radially extending over about 270°. The cylinder segment 1210 surroundsa circular cylindrical interior. Each of two lateral sections of thelongitudinal plate 1120 laterally project over the spacer 120 and,thereby, form a protrusion 1130.

On its bottom end, the cylinder segment 1210 of the spacer 120 passesover into a cylinder segment 1310 of a clamping portion of the containerconnector 130 via a step 140. The cylinder segment 1310 of the clampingportion of the container connector 130 also surrounds a circularcylindrical interior. The cylinder segment 1310 of the clamping portionof the container connector 130 has an inner diameter which is biggerthan an inner diameter of the cylinder segment 1210 of the spacer 120.Thus, the step 140 outwardly extends from the cylinder segment 1210 ofthe spacer 120 to the cylinder segment 1310 of the clamping portion ofthe container connector 130.

FIGS. 4AA′-4AE′ and FIGS. 4BF′-4BK′ show steps of a second embodiment ofa method for preparing a second embodiment of a double chamber staked-inneedle syringe 60 as container. The second method is implemented in asecond embodiment of a facility for preparing the syringe 60. Thesyringe 60 has a distal end side, a proximal end side opposite to thedistal end side and a cylindrical body portion 630 with an interiorbetween the distal end side and the proximal end side. A distal openingprovided with a needle is arranged at the distal end side. The needle iscovered and protected by a rigid needle shell 640.

The proximal end side of the syringe 60 has a proximal opening 610. Thedistal end side, the body portion 630 and the proximal end side areintegrally made of glass, i.e. are one piece. In a side wall of the bodyportion 630 a longitudinal vertical bulge is arranged as a bypass 620.

In the step of FIG. 4 AA′ of the second method a set of identicalsyringes 60 is obtained in a tub 30. Each syringe 60 is arranged in arespective seat 210 of a holder 20. The holder 20 has a rectangular baseplate 220 from which the seats 210 vertically and upwardly extend in theform of clamping fingers. The syringe 60 vertically extends through theseats 210 wherein the clamping fingers of the seat 210 are shaped anddimensioned to clamp and hold the syringe 60.

The tub 30 has a top border 310, a wider upper section 320 and anarrower lower section 340. Between the upper section 320 and the lowersection 340 a shoulder section 330 is formed. When being arranged in thetub 30, the base plate 220 of the holder lies on the shoulder section330 of the tub 30. Thereby, the seats 210 and the portions of thesyringe 60 being in the seats 210 lie in the upper section 320 of thetub 30 and the rest of the syringes 60 in the lower section 340 of thetub 30. For transporting the tub 30 together with plural identicalsyringes 60, for example for delivering the syringes 60 to a suitablefacility for preparing the syringes 60, the interior of the tub 30 canbe sealed by a foil being bonded to the border 310 of the tub 30. Likethis, the syringes 60 can be handled in a protected and sterile fashion.

In the step of FIG. 2 AB′ of the first method the holder 20 togetherwith the syringes 60 is transferred by a transporter of the secondfacility from the tub 30 to an alignment device 40 of the secondfacility. The transporter can be a robot such as a linear robot or anarm robot or the like. The alignment device 40 comprises a central mainplate 420 with flat top and bottom surfaces, an upper alignment plate410 on the top surface of the main plate 420 and a lower alignment plate430 on the bottom surface of the main plate 420. The upper alignmentplate 410 has a plurality of though bores 4110 corresponding to thearrangement of the seats 210 of the holder 20, the main plate 420 hasrespective through bores 4210 and the lower alignment plate 430 hasrespective through bores 4310. Adjacent through bores 4110, 4210, 4310of the upper alignment plate 410, the main plate 420 and the loweralignment plate 430 together form adjustment openings of the alignmentdevice 40.

For arranging the syringes 60 in the alignment device 40 the holder 20is placed on a top surface of the upper alignment plate 410 such thateach one of the seats 210 of the holder 20 is on top of an adjustmentopening of the alignment device 40. Thereby, the syringes 60 extendthrough the adjustment openings of the alignment device 40. The upperalignment plate 410 and the lower alignment plate 430 are laterallymovable along the top surface of the main body 420 or along the bottomsurface of the main body 420, respectively. Like this, the syringes 60can be precisely aligned by moving the upper and lower alignment plates410, 430 of the alignment device 40 such that, e.g., substances can beexactly delivered into the syringes 60 as described in the following.

Furthermore, the syringes 60 are positioned in a centering plate 50 ofthe second facility while being arranged in the alignment device 40. Thecentering plate 50 has recesses 510 located in correspondence with thelocation of the seats 210 of the holder 20. Each recess 510 is embodiedas a conical though hole formed such that the distal end sides of thesyringes 60 can be received and held.

In the step of FIG. 2AC′ a substance such as a liquid pharmaceuticalsubstance or particularly a liquid biopharmaceutical substance is fedinto the interior of each syringe 60. For this purpose, a discharge pipeof a substance dosing feeder 910 of the second facility is enteredthrough the proximal opening 630 into the interior of the respectivesyringe 60. Then the substance is filled into the interior of thesyringe 60 wherein the syringe 60 is precisely aligned by the alignmentdevice 40 in order to prevent leakage and contamination. The substanceis thereby lying on the bottoms of the interiors of the syringes 60,i.e. at the distal end sides of the syringes 60.

In the step of FIG. 4AD′ the distance between the alignment device 40and the centering plate 50 is reduced. Thereby, the syringes 60 arevertically lifted with respect to the alignment device 40 such thatlarger sections of the body portions 630 of the syringes 60 areaccessible above the seats 210 of the holder 20.

As shown in the step of FIG. 4AE′, when being held and stabilized by thecentering plate 50, on each syringe 60 one support of the devices 10 isimposed. In the through-hole of each of the supports a rubber plunger150 is arranged. Per syringe 60, the support of the device 10 is shiftedas far top down on the body portion 630 of the syringe 60 that the step140 abuts and slightly clamps the upper edge of the body portion 630.Like this the support is held on the syringe 60. The device 10 is in adistant position.

Turning to the step of FIG. 4BF′ the holder 20 together with thesyringes 60 is transferred by the transporter of the second facility toa freeze-drying block 70 of a freeze-dryer of the second facility.Thereby, the syringes 60 are clamped in the seats 210 of the holder 20.The freeze-drying block 70 is made of aluminium and has receptacles 710located in correspondence with the location of the seats 210 of theholder 20. Each receptacle 710 is embodied as a bore with a profileshaped to receive one of the syringes 60. In particular, the profiles ofthe receptacles 710 have a lower needle section 7110 dimensioned toreceive the rigid needle shield 640 of one of the syringes 60 and anupper body section 7130 dimensioned to contact the distal end of thebody portion 630 of the syringe 60. Between the needle section 7110 andthe body section 7130 a shoulder section 7120 is formed which isdimensioned to receiving the distal end side of the body portion 630 ofthe syringe 60. The top side of the body section 7130 passes over into aconical entrance section 7140 which allows for conveniently entering therespective syringe 60 into the receptacle 710.

When the syringes 60 are arranged in the receptacles 710 of thefreeze-drying block 70 heat is provided via the side walls of the bodyportions 7130 of the receptacles 710 and the side walls of the bodyportions 630 of the syringes 60 to the liquid substance being at thebottoms of the body portions 630 of the syringes 60. Like this, thesubstance inside the syringes 60 is lyophilised as described above forthe step of FIG. 2E the first method.

In the step of FIG. 4BG′, after lyophilisation of the substance, thesupports of the devices 10 are lowered on the syringes 60 and theplungers 150 are connected to the proximal openings 630 of the syringes60. The device 10 is now in a near position. Since the lyophilisationinduces an underpressure in the interior of the syringes 60 the plungers150 are sucked downwardly into the interior of the body portions 630 ofthe syringes 60. Thereby, the plungers 150 are arranged above thebypasses 620 of the syringes 60. Like this, two chambers are built inthe interior of each syringe 60, i.e. one distal chamber comprising thelyophilised substance and one proximal chamber. The plungers 150 sealthe proximal chambers from the distal chambers.

In the step of FIG. 4BH′ the holder 20 together with the syringes 60equipped with the supports of the devices 10 are transferred to andpositioned in the aligning device 40 and the centering plate 50.

In the step of FIG. 4BI′ a discharging pipe of a medium dosing feeder920 of the second facility is entered through the proximal opening 610into the interior of the respective syringe 60. The medium dosing feeder920 feeds a reconstitution medium or diluent in the proximal chamber ofthe syringe 60 wherein the syringe 60 is precisely aligned by thealignment device 40. After being fed, the reconstitution medium lies onthe top of the plungers 150 above the bypasses 620 of the body portions630 of the syringes 60.

In the step of FIG. 4BJ′ further plungers are pressed into the proximalopenings 610 of the syringes 60 by means of tubes 930 of a sealer of thesecond facility. Thereby, the proximal openings 610 of the syringes 60are sealed by the further plungers. The syringes 60 are still arrangedin the centering plate 50 wherein the distal end side of the bodyportions 630 abut the recesses 510. Like this, the pushing force inducedon the syringes 60 by the tubes 930 of the sealer is received by thecentering plate 50.

After the proximal openings 610 of the syringes 60 being sealed, theholder 40 together with the syringes 60 is transferred by thetransporter to an optical inspection station of the second facility.There, the quality of the lyophilised substance is verified.

In the step of FIG. 4BK′ the verified syringes 60 are transferred in theholder 20 to a tub 30 identical to the tub 30 they have initially beendelivered to the second facility. In the tub 30 the syringes 60 can bedelivered or shipped for further processing such as selling or the like.As shown hereinbefore, the syringes 60 are arranged in the seats 210 ofthe holder 20 in an upright position throughout the complete preparationprocess. This allows for an efficient handling and processing of pluralsyringes 60 which can be particularly useful on an industrial level.

In FIG. 5 a third embodiment of a device 18 according to the inventionis shown. The device 18 comprises a holder 118 and a support 128. Theholder 118 has an essentially squared holder base plate 1118 equippedwith ten rows of ten syringe cavities 1128 as container carriers whereineach two neighbouring rows are offset to each other. Each syringe cavity1128 is built as a vertical hollow cylinder extending from the holderbase plate 1118. In order to stabilize the arrangement of the syringecavities 1128 their cylinders are interconnected by ridges 1148. Theholder 118 is arranged for providing a plurality of nested syringes.

Laterally beside the syringe cavities 1128 hollow cylinders of holderparts 1138 of spacers vertically extend from the base plate 1118 of theholder 118. In particular, two holder parts 1138 of the spacers arelocated near each of the sides of the base plate 1118 such that theholder 118 is equipped with eight holder parts 1138.

The support 128 comprises an essentially squared support base plate 1218with through-holes as plunger seats 1228 being located in correspondencewith the position of the syringe cavities 1128 of the holder 118. Thethrough-holes have thickened rims which are interconnected by ridges1248. Near two of the sides of the support base plate 1218 two supportparts 1238 of the spacers are arranged. The four support parts 1238 arelocated in correspondence to the position of four of the holder parts1138 of the holder 118.

Each of the support parts 1238 of the spacers comprises two opposingcylinder segments 12318 being separated by a free space. The cylindersegments extend vertically from the support base plate 1218. Near theirtop ends each cylinder segment 12318 of the support parts 1238 has acircumference bulge 12328 on its outer surface.

FIGS. 6A″ to 6J″ of a third embodiment of a method for preparing a thirdembodiment of a double chamber staked-in needle syringe 68 as container.The third method is implemented in a third embodiment of a facility forpreparing the syringe 68. The syringe 68 is similarly shaped as thesyringe described hereinbefore with respect to FIGS. 4AA′-4AE′ and FIG.4BF′-4BK′. In particular, it has an identical body portion 638 with abypass 658 and a proximal opening 618, and a needle covered by a rigidneedle shield 648. Different from the syringe 60 of FIGS. 4AA′-4AE′ andFIGS. 4BF′-4BK′, the syringe 68 comprises a finger flange 628 around theproximal opening 618 of the body portion 638.

In the step of FIG. 6A″ of the third method a set of identical syringes68 is obtained in a tub 38. The tub 38 is identically embodied as thetub 30 of FIGS. 4AA′-4AE′ and FIGS. 4BF′-4BK′. In particular, it has anidentical top border 318, an identical wider upper section 328 and anidentical narrower lower section 348 wherein a shoulder section 338 isformed between the upper section 328 and the lower section 348.

Each syringe 68 is arranged in a respective syringe cavity 1128 of theholder 118 of the device 18. The syringes 68 vertically extend throughthe syringe cavities 1128 wherein the syringe cavities 1128 aredimensioned such that rigid needle shields 648, distal end sides and thebody portions 638 of the syringes 68 fit though the hollow cylinders butnot the finger flanges 628. Thus, the syringes 68 are arranged in thesyringe cavities 1128 of the holder 118 by vertically hanging though thehollow cylinders wherein the finger flanges 628 lie on the top end ofthe hollow cylinders of the syringe cavities 1128.

When being arranged in the tub 38, the holder base plate 1118 of theholder 118 lies on the shoulder section 338 of the tub 38. Thereby, thesyringe cavities 1128 and the portions of the syringes 68 being in thehollow cylinders lie in the upper section 328 of the tub 38 and the restof the syringes 68 in the lower section 348 of the tub 38.

On the border 318 of the tub 38 the support 128 is arranged. Eachplunger seat 1228 is equipped with one rubber plunger 158 whichdownwardly projects below the plunger seat 1228. Thereby, thethrough-holes of the plunger seats 1228 are dimensioned to releasablyhold the plungers 158 by friction. Each plunger 158 is located adjacentto and distant from one of the proximal openings 618 of the syringes 68.

In the step of FIG. 6B″ of the third method the nested plungers 158 areremoved together with the support 128 from the tub 38 in order that theholder 118 with the nested syringes 68 is accessible.

In the step of FIG. 6C″ the holder 118 together with the syringes 68 aretransferred by a transporter of the third facility from the tub 38 to analignment device 48 of the third facility. The transporter can be arobot such as a linear robot or an arm robot or the like. The alignmentdevice 48 is identically embodied as the alignment device 40 describedabove in connection with FIGS. 4AA′-AE′ and FIGS. 4BF′-BK′. Inparticular, it has an identical central main plate 428 with throughbores 4218, an identical upper alignment plate 418 with through bores4118 and an identical lower alignment plate 438 with through bores 4318.

For arranging the syringes 68 in the alignment device 48 the holder 118is placed on a top surface of the upper alignment plate 418 such thateach one of the syringe cavities 1128 of the holder 118 is on top of anadjustment opening of the alignment device 48. Thereby, the syringes 68extend through the adjustment openings of the alignment device 48.

In the step of FIG. 6D″ of the third method a substance such as a liquidpharmaceutical substance or particularly a liquid biopharmaceuticalsubstance is fed into the interior of each syringe 68. For this purpose,a discharge pipe of a substance dosing feeder 918 of the third facilityis entered through the proximal opening 638 into the interior of therespective syringe 68. Then the substance is filled into the interior ofthe syringe 68 wherein the syringe 68 is precisely aligned by thealignment device 48 in order to allow for preventing leakage andcontamination. The substance is thereby lying on the bottoms of theinteriors of the syringes 68, i.e. at the distal end sides of thesyringes 68.

In the step of FIG. 6E″ the support 128 together with the nestedplungers 158 are placed on top of the holder 118. Thereby, the supportparts 1238 of the spacers interengage with the holder parts 1138 of thespacers by clipping into a distant position as shown in more detailbelow. In this distant position the plungers 158 are exactly aligneddistant from the proximal openings 618 of the syringes 68.

In the step of FIG. 6F″ the holder 118 together with the syringes 68 andthe support 128 are transferred by a transporter of the third facilityto a freeze-drying block 78 of a freeze-dryer of the third facility. Thefreeze-drying block 78 is similarly embodied as the freeze drying block70 of FIGS. 4AA′-4AE′ and FIGS. 4BF′-4BK′. It is made of aluminium andhas receptacles 718 located in correspondence with the location of thesyringe cavities 1128 of the holder 118. Each receptacle 718 is embodiedas a bore with a profile shaped to receive one of the syringes 68. Inparticular, the profiles of the receptacles 718 have a lower needlesection 7118 dimensioned to receive the rigid needle shield 648 of oneof the syringes 68 and an upper body section 7138 dimensioned to contactthe distal end of the body portion 638 of the syringe 68. Between theneedle section 7118 and the body section 7138 a shoulder section 7128 isformed which is dimensioned to receiving the distal end side of the bodyportion 638 of the syringe 68. The top side of the body section 7138passes over into a conical entrance section 7148 which allows forconveniently entering the respective syringe 68 into the receptacle 718.Lyophilisation of the substance inside the syringes 68 by means of thefreeze-drying block 78 is identically performed as explained with regardto the step of FIG. 2E of the first method.

In the step of FIG. 6G″ of the third method, after lyophilisation of thesubstance, the support 128 of the device 18 is lowered on the holder 118and the syringes 68. In particular, the support parts 1238 of thespacers are further clipped into the holder parts 1138 of the spacers asdescribed in more detail below. The device 18 is now in a near position.Thereby, the plungers 158 are connected to the proximal openings 638 ofthe syringes 68. Since the lyophilisation induces an underpressure inthe interior of the syringes 68 the plungers 158 are sucked downwardlyinto the interior of the body portions 638 of the syringes 68. At theend, the plungers 158 are arranged above the bypasses 628 of thesyringes 68. Like this, two chambers are built in the interior of eachsyringe 68, i.e. one distal chamber comprising the lyophilised substanceand one proximal chamber. The plungers 158 seal the proximal chambersfrom the distal chambers.

In the step of FIG. 6H″ the holder 118 together with the syringes 60 andthe support 128 are transferred to and positioned in the aligning device48 again. Furthermore, the syringes 68 are positioned in a centeringplate 58 of the second facility while being arranged in the alignmentdevice 48. The centering plate 58 has recesses 518 located incorrespondence with the location of the syringe cavities 1128 of theholder 118. Each recess 518 is embodied as a conical though-hole formedsuch that the distal end sides of the syringes 68 can be received andheld.

In the step of FIG. 6I″ the proximal chambers of the syringes 68 areprovided with a reconstitution medium or diluent by means of adischarging pipe of a medium dosing feeder 928 of the third facility asdescribed above in connection with the step of FIG. 4BI′. In the step ofFIG. 6J″ the interior of the body portions 638 of the syringes 68 aresealed by further plungers pushed in by means of tubes 938 of a sealerof the third facility as described above in connection with the step ofFIG. 4BJ′.

FIG. 7 , FIG. 8 and FIG. 9 show how the support parts 1238 of the spacerand the holder parts 1138 of the spacers interengage. As can be seen bythe one support part 1238 and the one holder part 1138 shown in FIG. 7 ,in a preliminary position the support part 1238 is placed on top of theholder part 1138. In this position the sections of the cylinder segments12318 being below the bulges 12328 are introduced into the top section11318 of the hollow cylinder of the holder part 1138. The top section11318 of the hollow cylinder has a thickened wall in which acircumferential groove 11328 is formed. In the preliminary positionshown in FIG. 7 which is the position of the step of FIG. 6A″ thesupport 128 and the holder 118 are aligned and held distant to eachother but they are not connected. This allows that the holder 118 andthe support 128 can easily be removed from each other as done in thestep of FIG. 6B″.

In FIG. 8 the spacer is shown in the distant position of the device 18.Thereby, the cylinder segments 12318 of the support part 1238 areclipped in the hollow cylinder of the holder part 1138 such that thebulges 12328 of the cylinder segments 12318 lie in the groove 11328 ofthe top section 11318 of the hollow cylinder. In this position theholder 118 and the support 128 are connected together wherein they stillare distant from each other such that the plungers 158 and the syringes68 do not contact each other. The holder 118 and the support 128 are inthe distant position in the steps of FIGS. 6E″ and 6F″, particularlyduring lyophilisation.

FIG. 9 shows the spacer in the near position in which the cylindersegments 12318 of the support part 1238 are further advanced into thehollow cylinder of the holder part 1138. Like this the bulges 12328 ofthe cylinder segments 12318 engage behind the thickened top section11318 of the hollow cylinder. In the near position the plungers 158arranged in the plunger seats 1228 of the support 128 contact theproximal openings 618 of the syringes 68 arranged in the syringecavities 1128 of the holder 118 (not shown in FIG. 9 ). The holder 118and the support 128 are in the near position in the steps of FIGS. 6G″,6H″, 6I″ and 6J″ of FIG. 6 .

The steps of FIGS. 10A″′ to 10J″′ show a fourth embodiment of a methodfor preparing a fourth embodiment of a double chamber staked-in needlesyringe 69 as container by using a fourth embodiment of a device 19according to the invention. The fourth method is implemented in a fourthembodiment of a facility for preparing the syringe 69. The design of thesyringe 69 is identical to the syringe 68 described above in connectionwith FIGS. 6A″-6J″. In particular, each of the syringes 69 has anidentical body portion 639 with a bypass 659 and a proximal opening 619surrounded by a finger flange 629, and an identical needle covered by anidentical rigid needle shield 649.

The device 19 comprises a holder 119 and a support 129. The holder 119has an essentially squared holder base plate 1119 equipped with pluralrows of syringe cavities 1129 as container carriers. Each syringe cavity1129 is formed by a vertical hollow cylinder upwardly extending from theholder base plate 1119. Laterally beside the syringe cavities 1129holder parts 1139 of spacers are arranged on the base plate 1119 of theholder 119.

The support 129 comprises an essentially squared support base plate 1219with plunger through-holes 1229 as plunger seats being located incorrespondence with the position of the syringe cavities 1129 of theholder 119. Near the sides of the support base plate 1219 support parts1239 of the spacers are arranged at positions corresponding to thepositions of the holder parts 1139 on the holder 119. Adjacent to eachof the plunger through-holes 1229 an access through-hole 1249 isprovided in the support base plate 1219 of the support 129.

In the step of FIG. 10A″′ of the fourth method the holder 119 togetherwith the syringes 69 and the support provided with rubber plungers 159in the plunger through-holes 1229 are obtained in a tub 39. The tub 39is identically embodied as the tub 30 of FIGS. 4AA′-4AE′ and FIGS.4BF′-4BK′. In particular, it has an identical top border 319, anidentical wider upper section 329 and an identical narrower lowersection 349 wherein a shoulder section 339 is formed between the uppersection 329 and the lower section 349. The syringes 69 are verticallyhanging in the syringe cavities 1129 as described above in connectionwith the step of FIG. 6A″. Also the holder 119 and the support 129 arearranged in the tub 39 as described above in connection with the step ofFIG. 6A″.

In the step of FIG. 10B″′ of the fourth method the holder 119 with thenested syringes 69 and the support 129 with the nested plungers 159 aretogether lifted out of the tub 39 and arranged in an alignment device 49of the fourth facility. The alignment device 49 is identically embodiedas the alignment device 40 described above in connection with FIGS.4AA′-4AE′ and FIGS. 4BF′-4BK′. In particular, it has an identicalcentral main plate 429 with through bores 4219, an identical upperalignment plate 419 with through bores 4119 and an identical loweralignment plate 439 with through bores 4319.

The holder 119 and the support 129 are connected to each other in adistant position of the device 19 via the spacers. In this distantposition the access through-holes 1249 of the support are locatedvertically above the proximal openings 619 of the syringes 69.Correspondingly, the plungers 159 are vertically offset with respect tothe proximal openings 619 of the syringes 69.

For arranging the syringes 69 in the alignment device 49 the holder 119is placed on a top surface of the upper alignment plate 419 such thateach one of the syringe cavities 1129 of the holder 119 is on top of anadjustment opening of the alignment device 49. Thereby, the syringes 69extend through the adjustment openings of the alignment device 49.

In the step of FIG. 10C″′ of the third method a substance such as aliquid pharmaceutical substance or particularly a liquidbiopharmaceutical substance is fed into the interior of each syringe 69.For this purpose, a discharge pipe of a substance dosing feeder 919 ofthe fourth facility is entered via the respective access opening 1249 ofthe support 129 through the proximal opening 619 into the interior ofthe respective syringe 69. Then the substance is filled into theinterior of the syringe 69 wherein the syringe 69 is precisely alignedby the alignment device 49 in order to prevent leakage andcontamination. By means of the access openings 1249 the interior of thesyringes 69 can be straightly and efficiently reached by the dischargepipe of the substance dosing feeder 919.

In the step of FIG. 10D″′ the holder 119 together with the syringes 69and the support 129 are transferred by a transporter of the fourthfacility to a freeze-drying block 79 of a freeze-dryer of the fourthfacility. The freeze-drying block 79 is identically embodied as thefreeze drying block 78 of FIGS. 6A″ to 6J″. It is made of aluminium andhas identical receptacles 719 with a profile shaped to receive one ofthe syringes 69. In particular, the profiles of the receptacles 719 havean identical lower needle section 7119, an identical upper body section7139, an identical shoulder section 7129 in between and an identicalconical entrance section 7149. Lyophilisation of the substance insidethe syringes 69 by means of the freeze-drying block 79 is identicallyperformed as described with regard to the lyophilisation shown in FIGS.4AA′-4AE′ and FIGS. 4BF′-4BK′ wherein the support 129 and the holder 119are connected in the distant position.

In the step of FIG. 10E″′ of the fourth method, after lyophilisation ofthe substance, the support 129 of the device 19 is lowered onto theholder 119 and the syringes 69. As explained in more detail below, bymeans of the spacers the support 129 is lowered diagonally onto theholder 119 to a near position such that in the near position each of theplungers 159 is located at a proximal opening 639 of one of the syringes69. Thus, the distance between the support 129 and the holder 119 isreduced at the same time as they are laterally shifted to each other.

In the step of FIG. 10F″′ the plungers 159 are connected to the proximalopenings 639 of the syringes 69 in the near position of the spacers.There, an underpressure in the interior of the syringes 69 resultingfrom lyophilisation sucks the plungers 159 downwardly into the interiorof the body portions 639 of the syringes 69. At the end, the plungers159 are arranged above the bypasses 629 of the syringes 69 and twochambers are formed in the interior of each syringe 69, i.e. one distalchamber comprising the lyophilised substance and one proximal chamber.

In the step of FIG. 10G″′ of the fourth method the holder 119 togetherwith the syringes 69 and the support 129 are transferred to andpositioned in the aligning device 49 again. In the step of FIG. 10H″′the proximal chambers of the syringes 69 are provided with areconstitution medium or diluent by means of a discharging pipe of amedium dosing feeder 929 of the fourth facility as described above inconnection with the step of FIG. 4BI′.

In the step of FIG. 10I″′ the interior of the body portions 639 of thesyringes 69 are sealed by further plungers pushed in by means of tubes939 of a sealer of the fourth facility as described above in connectionwith the step of FIG. 4BJ′. Thereby, the pushing force induced by thetubes 939 is received by the alignment device 49 via the finger flanges629 of the syringes 69 and the syringe cavities 1129 of the holder 119.

In the step of FIG. 10J″′ the prepared syringes 69 are transferred inthe holder 119 to a tub 39 identical to the tub 39 they have initiallybeen delivered to the fourth facility. In the tub 39 the syringes 69 canbe delivered or shipped for further processing such as selling or thelike.

FIG. 11 shows the spacer of the device 19 in an unconnected, separatedor preliminary position. The preliminary position is present in the stepof FIG. 10A″′. It comprises the support part 1239 and the holder part1139. The support part 1239 has a slider mount 12319 which conicallyextends from the support base plate 1219. At a bottom portion of theslider mount 12319 a slider 12329 is connected which perpendicularlyextends from the slider mount 12319. The slider 12329 is embodied as apost.

The holder part 1139 vertically extends from the holder base plate 1119in an upward direction. It comprises a lower base section 11339connected to the holder base plate 1119 from which a diagonal ramp 11319upwardly extends. At a bottom end of the ramp 11319 a near fastener11349 is embodied as recess in the base section 11339. At a top end, theramp 11319 passes over into a distant fastener 11329 embodied as aC-shaped clamping hook.

In FIG. 12 the spacer of the device 19 is shown in the distant position.In this position the slider 12329 is snapped in and clamped by thedistant fastener 11329. Thus, the holder 119 and the support 129 arereleasably connected to each other in the distant position. The distantposition of the device 19 is present in the steps of FIGS. 10B″′, 10C″′and 10D″′.

FIG. 13 shows the spacer of the device 19 after the slider 12129 istravelled downwardly along the ramp 11319. During such travel thesupport 129 is on one hand moved towards the holder 119 and on the otherhand laterally shifted with respect to the holder 119.

In FIG. 14 the spacer is shown in the near position in which the slider12129 is pressed into the near fastener 11349 in which it is clamped andsecured. In this position the top of the distant fastener 11329 abutsthe lower surface of the support base plate 1219. The near position ispresent in the steps of FIGS. 10E″′ to 10J″′.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, such illustration and descriptionare to be considered illustrative or exemplary and not restrictive. Itwill be understood that changes and modifications may be made by thoseof ordinary skill within the scope and spirit of the following claims.In particular, the present invention covers further embodiments with anycombination of features from different embodiments described above andbelow. Various mechanical, compositional, structural, electrical, andoperational changes may be made without departing from the spirit andscope of this description and the claims. In some instances, well-knowncircuits, structures, and techniques have not been shown in detail inorder not to obscure the invention. Like numbers in two or more figuresrepresent the same or similar elements.

The invention also covers all further features shown in the FIGS.individually although they may not have been described in the afore orfollowing description. Also, single alternatives of the embodimentsdescribed in the figures and the description and single alternatives offeatures thereof can be disclaimed from the subject matter of theinvention or from disclosed subject matter. The disclosure comprisessubject matter consisting of the features defined in the claims or theexemplary embodiments as well as subject matter comprising saidfeatures.

Furthermore, in the claims the word “comprising” does not exclude otherelements or steps, and the indefinite article “a” or “an” does notexclude a plurality. A single unit or step may fulfil the functions ofseveral features recited in the claims. The mere fact that certainmeasures are recited in mutually different dependent claims does notindicate that a combination of these measures cannot be used toadvantage. The terms “essentially”, “about”, “approximately” and thelike in connection with an attribute or a value particularly also defineexactly the attribute or exactly the value, respectively. The term“about” in the context of a given numerate value or range refers to avalue or range that is, e.g., within 20%, within 10%, within 5%, orwithin 2% of the given value or range. Any reference signs in the claimsshould not be construed as limiting the scope.

What is claimed is:
 1. A device for closing a chamber of a containerhaving an opening for accessing the chamber, comprising: a plunger; aspacer; a support comprising a plunger seat and a support part of thespacer; and a holder comprising a container carrier and a holder part ofthe spacer, wherein the plunger seat of the support releasably holds theplunger in a predefined alignment, the container carrier of the holderis arranged to be connected to the container in a predefined positionand alignment in relation to the opening of the container, the spacer isarranged to predefine a position and alignment of the plunger seat inrelation to the container carrier, in a predefined distant position ofthe device, the plunger seat of the support is located distant from theopening of the container when the container is connected to thecontainer carrier of the holder such that the opening of the containeris open, in a predefined near position of the device, the plunger seatof the support is arranged adjacent to the opening of the container whenthe container is connected to the container carrier of the holder suchthat the plunger is providable into the opening of the container forclosing the container, the support part of the spacer and the holderpart of the spacer are arranged to interengage by forming a snap-inconnection to be connected in the predefined distant position of thedevice and to be connected in the predefined near position of thedevice, the snap-in connection is formed by the support part beingreceived within a portion of the holder part, and the support comprisesat least one further plunger seat and a support base plate on which theplunger seat, the at least one further plunger seat, and the supportpart of the spacer are arranged.
 2. The device according to claim 1,wherein the snap-in connection formed by the holder part of the spacerand the support part of the spacer is arranged to connect the holderpart of the spacer and the support part of the spacer in plural distinctpositions.
 3. The device according claim 1, wherein the holder part ofthe spacer comprises an inclined ramp and the support part of the spacercomprises a slider, wherein the slider is movable along the inclinedramp from the predefined distant position in which the plunger seat ofthe support is distant and laterally displaced from the containercarrier of the holder to the predefined near position in which theplunger seat of the support is adjacent and straightly directed to thecontainer carrier of the holder, wherein the second distance is smallerthan the first distance.
 4. The device according to claim 1, wherein theholder has a holder base plate on which the container carrier and theholder part of the spacer are arranged.
 5. The device according to claim1, wherein the holder comprises at least one further container carrier,wherein the plunger seat and the at least one further plunger seat arelocated on the support in correspondence with the container carrier andthe at least one further container carrier of the holder.